check engine ISUZU KB P190 2007 Workshop Manual Online

6C – 12 FUEL SYSTEM

Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from fuel gauge unit.



140R100035
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.


Installation
1. Clean the seal surface of the fuel tank and the fuel gauge unit.
NOTE: If there is dust on the seal surface, it becomes cause o
f
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.


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ISUZU KB P190 2007

FUEL SYSTEM 6C – 15


140R100037
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.





140R100028
Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.






140R100036
Reuse of Quick–Connector
• Replace the port and connector if scratch, dent or crack is
found.
• Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms o
f
rust, dent, scratch.
• After cleaning the port, insert it straight into the connecto
r
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.


Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability). Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.





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6D – 12 ENGINE ELECTRICAL
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.

ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting. Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter mm (in)
Standard Limit



RTW06DSH000101
31.6 (1.245) 30.6 (1.183)















If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.

3. Measure the rotor coil resistance.
Rotor Coil Resistance at 20 °C (68 °F) ohms
Standard 3.8



RTW46DSH001001







RTW46DSH001101
4. Check for continuity between the slip rings and the
rotor core or shaft.
If there is continuity, the entire rotor assmbly must be
replaced.



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ENGINE ELECTRICAL 6D – 13
STATOR COIL ASSEMBLY
1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal “N ” and the Coil Ends
(Reference) ohms
Standard 0.1

066RY00022 2. Check for continuity between each stator coils and the stator core.
If there is continuity, the stator coils must be replaced.
066RY00023


RTW46DSH004801
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference) mm (in)

Standard Limit
25 (1.0) 6.5 (0.25)



RTW46DSH001201
Rectifier


Tester wire
E BAT
U, V, and WN ⊕  U, V, and WN⊕ 
⊕ ----- Conductivity ⊕ ----- No
conductivity

No
conductivity -----

Conductivity -----
Negative side diode check Positive side diode check



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6D – 14 ENGINE ELECTRICAL
RECTIFIER ASSEMBLY



RTW46DSF000301

1. Voltmeter
2. Switch 1
3. DC regulated power supply
4. Lamp 2
5. Lamp 1
6. Switch 3
7. Switch 2
8. Pulse generator
9. Output signal

Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1~5. If all the items are OK, the IC
regulator is normal.

Circuit components
1 DC regulated power supply 0~20 volts variable with output of 1 ampere or more
2 Lamps (2)
12 volts, 1.4~3.4 watts
3 Switches (3)
-----
4 DC voltmeter
0~30 volts, 0.5 grade
5 Pulse generator (Oscillator)
5~30 volt output at a frequency of 1kHz

Judgment criteria
Lamp condition
No. Switch
1 Switch
2 Switch
3 Voltmeter
reading Lamp 1 Lamp 2 Remarks
1
ON OFF OFF On
(dim) ON Initial excitation check
2
ON ON OFF 12V
On or
flashing Full excitation check
3
ON ON OFF 16V Off or
on (dim) OFF
Lamp 1 off or dimly lit when the
voltmeter shows less than 12 volts or
16 volts
4 OFF ON OFF 12V On or
flashing Stator and brush separation check
5
ON ON ON 18V On ON
Excess voltage check

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ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.


Oil Seal Replacement
1. Push the old oil seal from the rear bracket outside holes.
2. Use the insertion tool to press the new oil seal into place. Follow the procedure shown in Figures A, B, C
and D.

Position the oil seal beneath the shaft and the
guide lip.

Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.

After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution







Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.







Take care not to damage the D surface.







Under no circumstances may the original oil seal
be reused.







The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.







RTW46DSF000101

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ISUZU KB P190 2007

6D – 16 ENGINE ELECTRICAL



RTW46DSH000901

















Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump housing.
2. Remove the vacuum pump rotor and the vanes from the housing.


Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.



Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.


Rotor
1. Inspect the rotor for excessive wear, abrasion, and scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash. Replace the rotor if backlash is present.














RTW46DSH005201
Check Value
1. Carefully force the valve from the
“B ” side as shown in
the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the “A ” side.
Air Pressure kPa (kg/cm
2/psi)
98 - 490 (1-5/14 – 71)

Check for air leakage from the check valve.
If there is air leakage, the valve must be replaced.

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ENGINE ELECTRICAL 6D – 21




RTW06DSH000201











9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the front cover and the rear cover.
2. Install the through bolts and tighten them to the specified torque.
Through Bolt Torque N ⋅m (kg ⋅m/lb ⋅ft)
3.1 ∼ 3.9 (0.32 ∼ 0.41 / 2.6 ∼ 3.5)


11. Vaccum Pump To install the generator -

1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the 3 generator fixing points.
3. Twist the fixing points down and to the left to align them with the middle of the center plate and the rotor.




RTW46DSH006101
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.



RTW46DSH002401
Install the vacuum pump housing.
Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.



RTW46DSH002501












Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque N ⋅m (kg ⋅m/lb ⋅ft)
5.9 ∼ 6.9 (0.6 ∼ 0.7 / 5.2 ∼ 6.1)




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6D – 26 ENGINE ELECTRICAL
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.

ARMATURE
1. Measure the commutator run-out. Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out mm (in)
Standard Limit
0.05 (0.002) 0.2 (0.008)


RTW46DSH003501











2. Check the commutator mica segments for excessive
wear.
3. Measure the mica segment depth.
Mica Segment Depth mm (in)
Standard Limit
0.5 ∼ 0.8 (0.020 ∼ 0.030) 0.2 (0.008)
065RY00025








If the mica segment depth is less than the standard but
more than the limit, the commutator may be reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.

4. Measure the commutator outside diameter.
Commutator Outside Diameter mm (in)
Standard Limit
36.5 (1.44) 35.5 (1.40)





If the measured outside diameter is less than the specified
limit, the commutator must be replaced.
065RY00026

RTW46DSH003601
5. Use a circuit tester to check the armature for
grounding.
1 Hold one probe of the circuit tester against the commutator segment.
2 Hold the other circuit tester probe against the armature core.
If the circuit tester indicates continuity, the armature is grounded.
The armature must be replaced.


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ENGINE ELECTRICAL 6D – 27


RTW46DSH003701
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two commutator segments.
2 Repear Step 1 at different segments of the armature core.
There should be continuity between all segments of the commutator.
If there is not, the armature must be replaced.




RTW46DSH003801
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field winding end or brush.
2 Hold the other circuit tester probe against the bare surface of the yoke body.
There should be no continuity. If there is continuity, the field coil is grounded.
The yoke must be replaced.



RTW46DSH003901
2. Use the circuit tester to check the field winding
continuity.
1 Hold one circuit tester probe against the “M ”
terminal lead wire.
2 Hold the other circuit tester probe against the field winding brush.
There should be continuity. If there is no continuity, the yoke must be replaced.


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